Troughing idler assembly



Nov. 23, 1965 B. H. ECKHARDT ETAL 3,219,174

mouenme IDLER ASSEMBLY Filed June 26, 1961 3 Sheets-Sheet 1 38 William E Herrmann Bruno H. Eckhordf TTORNEY B. H. ECKHARDT ETAL TROUGHING IDLER ASSEMBLY FIG. 4.

' Nov. 23, 1965 Filed June 26, 1961 FIG.

FIG. 8.

Y Bruno H. Eckhcrdf FIG 5 2: 2b 84 \so L (82 i} 7 7 Nov. 23, 1965 Filed June 26, 1961 B. H. ECKHARDT ETAL 3,219,174

TROUGHING IDLER ASSEMBLY 3 Sheets-Sheet 5 INVENTORS Bruno H. Eckhardi William E, Herrrnann United States Patent 3,219,174 TROUGHING IDLER ASSEMBLY Bruno H. Eckhardt, 217 S. Pickering Ave., Whittier,

Calif., and William E. Herrmann, 828 Edel Ave., Maywood, NJ.

Filed June 26, 1961, Ser. No. 123,926 16 Claims. (Cl. 198-192) This application is a continuation-in-part of application Serial No. 42,297, filed July 12, 1960, now abandoned, titled Troughing Idler Assembly.

This invention pertains to belt conveyor idler assemblies which are adapted to be supported on side frames. The side frames may either be of the rope side frame type as shown in McKinlay Patent No. 1,748,301 or of the flexible tubular type as shown in Kendall Patent No. 2,179,187. On the other hand, certain features of our invention are also capable of use in idlers for the more rigid deck type of installations.

Many forms of idlers have been developed for conveyors of the types shown in these two patents. Some of these idlers may be referred to as being completely flexible. Others are of the type wherein the rollers or rolls are relatively movable with respect to each other but in which a rigid framework is employed to maintain a relatively fixed distance between the opposite ends of the idler. In yet another form of idler, such as those of the Kendall patent, the rolls are fixedly positioned within the rigid frame work which interconnects the side frame members of the conveyor. The idler constructed in accordance with the teachings of my invention is of the latter type.

Idlers of this type are used in many installations. Among their advantages are their rigidity, adaptability to fixed trough, and their relatively high load carrying capacity. One disadvantage of heretofore known idlers of the instant type, however, is that they have been relatively expensive as compared to other known idlers. Accordingly, one object of the instant invention is to provide an idler which may be relatively inexpensively produced and sold. Thus an idler as herein provided will provide the advantages of rigid interconnection of the side frames and increased belt carrying capacity, yet its cost will be within acceptable limits as compared with previously known idlers of the same type.

One difficulty with prior known rigid frame idlers, particularly as employed in rope frame conveyors, is due to the presence of frame elements below the idler rolls. This factor necessarily increases the overall height of a conveyor. Therefore a still further object of the invention is to provide an idler wherein the frame elements extend alongside of the idler rollers, thus making it possible to reduce the overall height of the idlers and a conveyor in which they are installed.

A further disadvantage is also inherent in idlers having depending frame elements; namely, when the latter type are employed in rope type frame conveyors, great care must be exercised to insure that they will not strike the return run of the belt. This requires more stands and maintenance of a greater vertical distance between the idlers for the upper run and the lower reach of the belt than that dictated by idler height alone. Accordingly, one further object of the instant invention is to provide an idler construction with which reduced vertical spacing of the idlers with respect to the lower run of the belt and increased longitudinal spacing with respect to the stands 1 are possible.

Yet a further object is to provide an idler structure wherein the lower run of the belt will not be damaged should the idler strike the upper surface of the lower' reach of the belt.

Still another object is to provide an idler which will permit wider spacing of idlers along the side frames of conveyors.

Another object is to provide an idler structure which can be formed of relatively simple sheet stock, and which can be easily fabricated by simple known methods. A similar object is to provide a simple means for mounting the idler rollers in the idler frame which is relatively inexpensive, which facilitates quick assembly, and yet provides rigid support and has adequate strength.

Previously developed rigid frame idlers have in many instances been of welded construction and have employed tubular elements which are, relatively speaking, more expensive than flat sheet or bar stock and they are also more diflicult to weld or attach than fiat or bar stock. Further welding creates stress concentrations which must be relieved and pits and pockets which are apt to induce corrosion. Accordingly, we have, as another object of our invention, that of providing an idler structure having a frame formed of plain bar and sheet stock. Furthermore, although it will be apparent from a review of the instant disclosure that welding can be utilized wherever deemed desirable, our idler will be adequately strong and otherwise satisfactory for its intended purposes without the use of welding. It will be apparent that welding can be employed with an idler constructed according to our invention for the purpose of attaching auxiliary members or fixtures or for other purposes in installations where such may be desirable or necessary.

Still a further advantage obtained by the instant invention is that we provide rigidly mounted idler rollers in an idler which can be assembled relatively cheaply and quickly, and wherein repair and replacement of parts can be greatly facilitated, as compared with prior known gidlers of a similar type. This is in part due to the use of a non-welded construction, particularly in the means of interconnecting the rigid cross frame elements with the conveyor side frame mounting means. A further object and advantage of the instant invention is that we provide continuous cross frame elements extending from end brackets which are connected to the latter and in which no Welding is required. Yet another object of our invention is to provide a structure in which the idler rollers are transversely rigid and are rigidly supported in a transverse frame, yet wherein adjustment of the rigidly interconnected and supported idler rollers with respect to the rigid frame and to load variations is possible without undue strain on the assemblage. A further object and advantage is the provision of an easily assembled structure having a rigid frame and rigid idler roller assembly wherein these two rigid units can be readily interconnected. The idler roller assemblage is also rigidly supported without any strains being placed on the assembled idler.

Yet a further object of the invention is to provide idler roll mounting structure which cooperates with the frame in providing an idler of increased strength. Thus the roll mounting structure contributes to the strength of the frame structure, in addition to providing a means for rotatably supporting idler rolls. A related object is to provide end supports for idlers which support end rolls in fixed troughed position, and which function in forming a part of the rigid frame of the idler. Still another object is to provide a rigid truss-like construction as set forth above which is of light weight as compared to prior known idlers and is thus more easily attached in setting up a conveyor, or detached for movement to another location or for repair or replacement. Yet a still further, yet related, object is to provide a balanced idler construction in which the load is suspended uniformly from the ends of the idler. We also have in mind as an object to provide an idler structure including a central horizontal pulley or roller which has its belt contacting periphery supported substantially tangentially to the plane containing the side frame construction to which the idler is to be attached. This puts the frame (rope or rigid) and the belt line at about the same elevation for easier handling of men and material. Yet another related object is to provide a structure which is an open construction, thereby facilitating inspection, and one which can be easily repaired.

It is also an object to provide an idler wherein the idler rolls can be lubricated with one shot. One other similar object is to provide a structure in which the lubrication fitting is readily accessible'to a man standing at one side of the conveyor and is also at a point near the top of the conveyor and load. According to the instant invention the lubrication fitting is at the highest point of the idler above the side frame 'of the conveyor and directly facing to one outermost side of the conveyor.

An additional object is to provide a balanced idler structure having minimum gaps between idler rolls.

A further object is to provide a frame construction which will not damage the belt if the belt should run off. Although possibility of the latter occurring is reduced to a minimum with the instant invention, idlers constructed according to the instant invention will be less likely to damage the belt than previously known structures of a similar type.

These and other objects and advantages will become apparent from the following description and the accompanying drawings wherein:

FIGURE 1 is a fragmentary perspective view of a troughing idler assembly embodying our invention and a portion of an upper run of a conveyor.

FIGFURE 2 is a fragmentary top plan view of one end of the idler on a larger scale.

FIGURE 3 is a side view, partly sectioned, of the end shown in FIGURE 2.

FIGURE 4 is a side elevational view, partly in section, of a portion of the idler on a larger scale than that used for FIGURES 1 thru 3.

FIGURE 5 is a fragmentary top plan view of a center bracket and portions of the adjacent rollers and the shafts thereof which are supported in part by the bracket.

FIGURE 6 is an end view showing the relationship of a side frame and the center idler roller.

FIGURE 7 is a view taken along line 7-7 of FIG- URE 5.

FIGURE 8 is a partial side elevation on a smaller scale showing the relationship assumed between the center roller and a side frame.

FIGURE 9 is a fragmentary side elevation of another form of the invention.

FIGURE 10 is a perspective view of another form of idler constructed according to the invention.

FIGURE 11 is a fragmentary side elevation of the idler of FIGURE 10.

FIGURE 12 is a sectional view taken along line 12 12 of FIGURE 11.

There are many advantages to having a simple idler construction of light weight, yet of adequate strength, with which repairs can be easily made and yet which performs the conveying function in a most eflicient manner. The instant invention provides such a structure and will greatly increase the facility with which conveyors can be erected and moved. Further lubrication and inspection will be facilitated and the conveyor will function properly with less run-off and better control of the belt troughing and load. In addition, the idler will provide easier handling of men and materials due to its balanced construction. Referring now in particular to the drawings:

An idler 10 embodying these desirable features and constructed in accordance with the invention, is illustrated as suspended from a pair of side frame elements 12 and 14. The members 12 and 14 can be ropes or bars. For purposes of illustration ropes are employed.

The idler frame comprises a pair of side bars 16 and 18. These bars extend parallel to each other. They have a substantially straight central section and are provided with end flanges 22 attached to the central section by reversely curved sections 24. The end flanges 22 are displaced upwardly with respect to the central sections 20, and thus comprise upwardly extendings legs 26. (See FIGURE 3.)

Each of the side bars is also preferably provided with a laterally extending flange 28 extending along the lower edge thereof throughout the central section. It is apparent that the bars can be formed out of flat stock, and the various flanges and sections can be formed therein by simple pressing or bending operations.

The two side bars connect to an end bracket 30 at each end of the idler. The end brackets at opposite ends of the idler are exact duplicates of each other. Each end bracket comprises a central web 32. The central web has a base section 34, and a laterally extending end flange 36. The outer end of the latter flange is bent downwardly substantially parallel to base section 34 to form a lower clamp flange 38. The end flange 36 in itself also functions as a clamp flange and the bight 40 between flanges 36 and 38 forms a side frame receiving groove. The base section 34 is cut back as indicated at 42 and 44 in FIGURE 2 and a pair of facing parallel gussets are formed by bending the cut out end portions of the central web upwardly until they are substantially perpendicular to the base section 34. The lower ends of the gussets abut the flange 36, and can be welded thereto if desired.

The side bars and end brackets are adapted to be rigidly connected to each other by pairs of bolts and appropriate nuts 50 and 52.

The base sections of the end brackets are provided with hexagonally shaped openings 54 adjacent their upper ends. These are adapted to receive hexagonal end caps 56. The end caps are connected to the shafts of the outer idler rolls 58. The end caps close the outer ends of the shafts of the rolls 58. These shafts are formed of hollow, tubular pipe stock. Thus the caps seal the ends of the interconnected shaft formed by the three roll shafts and brackets 64.

The idler comprises 3 pulley rolls or rollers; namely, the outer rollers 58 and a central roller 60. The outer rollers are angled with respect to the central roller to provide a permanent trough. The end brackets and outwardly extending legs 26, as well as the center brackets, which are described below, can easily be altered to change the troughing angle. Each of the rollers is mounted on fixed spindles or axles such as 62 and 63. The end cap 56 is connected to the axle 62 for the outer idler 58. The ends of the idler rollers are of identical construction. Each end has a bearing supported on the axle 62. A lock sleeve 66 and a seal sleeve 67 also comprise part of the end construction, and the end cap slides onto the two sleeves 66 and 67.

The inner end of the axle 62 is secured to a center bracket 64. There are two center brackets provided, one on each side of the center roller. These center brackets comprise two arms. Each end of the axle 63 of the center roller 60 is secured in one of the arms 70 of each of the center brackets. Openings 68 are provided in the arms 70 for this purpose. The other arms 72 of the center brackets receive the inner ends of the outer axle 62 in similar openings. The axle ends (sleeves 66 and 67) slide into these openings. The center brackets are tightly connected to the end of the axles 62 and 63, preferably the connections are locked through the use of lock screws 74. Once rigidly interconnected the brackets and axles form a rigid roller support structure.

Each of the center brackets has oppositely extending pintles 76 and 78, projecting from the opposite sides thereof. The side bars have opposed openings 80 at properly spaced intervals, each adapted to receive a respective one of the pintles. The openings 80 are substantially larger in diameter than the pintles 76 and 78 and the latter can thus be readily inserted into the openings. Openings 80 are also elongated lengthwise of the bars 16 and 18. Each of the pintles has a laterally extending opening 82 which is adapted to receive a pin 84. A force fit is provided for the pin.

The idler is assembled by first assembling the center brackets and pulley shafts and then the end caps. Then the pintles of the center bracket are placed through the side bars and the pins 84 inserted and pinned. Next, the end brackets are placed over the end caps and attached to the side bars. The pulleys are pre-assembled onto the axles. The idler rolls are thus connected to the frame in a rigid manner, yet the idler is of relatively simple construction and easy to assemble. Further, it is apparent that repairs can be readily accomplished. The oversize holes 80 permit adjustment of the rollers and the center brackets to the side bars and eliminate the need for close tolerances. This is also true of the end cap-end bracket construction. This structure permits adjustment under load as well, yet a rigid, strong idler is produced.

Each end bracket is provided with a rope clamp structure 86. In this instance the rope clamp comprises an L-shaped bolt 90 adapted to cooperate with clamp nuts 92.

The bight 40 is positioned with respect to the top of the center roller 60 so that the horizontal plane intersecting the periphery of the roller extends approximately through the center of a frame member received within bight 40. See FIGURE 8 where this is shown by line 94. This positions the belt line, at its center, at about the same elevation as the side frames. This provides better balance of the idler on the side frame and increases the belt training ability of the idler. The canted side rollers extend upwardly from the belt line and will provide training whenever they tip in the direction of belt travel.

The arms 70 and 72 of the center bracket construction are received within the rollers, while the pintles are at the point of intersection of the roller axles. Their size and positioning at this point makes it possible to bring the upper edges of the rollers into close proximity and this provides minimum spacing between the rollers. This provides maximum protection for the load-carrying belt. The rounded roller edges also protect the belt from damage. In the event that run-01f should occur, the belt is further protected from damage due to the fact that the end brackets are below the periphery of the outer rollers. Further, the upper flanges of the latter brackets are curved complementary to the rollers.

Greasing of the idler is accomplished from one side. The axles 62, 66 and the center brackets are hollow throughout. The axles are also provided with suitable openings adjacent their ends through which grease can be forced into the bearings.

The center brackets and the end caps, it should be noted, rigidly support the idler roller assemblage. Further, the idler roller assemblage consisting of the center brackets and the inter-connected shafts can move slightly with respect to the cross bar 20 and the end caps. This not only facilitates assemblage, but acts as a means of preventing undue localized stress during the operation of the conveyor such as when the side bars deflect slightly under the load and particularly under a shock load. This construction, it also should be noted, greatly reduces the cost of machining, and the idler, considering these factors, as well as the absence of welding, can be relatively economically produced as compared to prior known devices. This is particularly true as compared to those requiring casting, welding facilities, and expensive welding time. Also, it is apparent that repairs can be greatly facilitated and the idler structure can be easily inspected. Furthermore, although the assemblage can be put together quickly and relatively simple structural elements are employed, the idler is a rigid device in the true sense of the word and there are no supports permitting upward movement of the idler rollers individually with respect to their supports.

Also, the belt is supported uniformly by a line of roller support which extends laterally straight across the belt, thus it is a single line. This is superior to supporting a portion of the belt at one point and another portion laterally placed with respect to the first portion at a distance spaced along the belt from the point of support of the first portion. It will be apparent that there will be a saving in belt wear and an extension in belt life by virtue of the instant structure, as compared to that in which the belt is supported only partially at one point.

In the form illustrated in FIGURE 9, the side bars can have their upper central horizontal edges placed at or below center line 96 of the central rollers 98. This places the gap between the roller and the bar at or below the maximum width of the roller. There will be less likelihood of dirt or debris catching between the bar and the roller on the downcoming side of the roller with such construction. This will result from the fact that the space between the roller and bar increases below the upper edge of the bar in such constructions.

As mentioned above, the central idler roller projects downwardly beneath the side bars and its belt contacting periphery at its uppermost point is substantially in line with the side frame receiving chamber formed by the clamp bolt 90 and its two cooperating flanges. These features provide stabilization, lower the center of gravity of the idler with respect to the side frames, provide good training action, prevent damage to the belt in the return run and permit lower overall conveyor height.

FIGURES 10, ll, and 12 show another form of idler embodying features of our invention. This form also shows the utilization of the side bars as end bracket web stiffening means and a simplified end bracket construction. In this instance the side bars 100 have their ends 102 bent inwardly to form flanges extending parallel to the vertical legs 104 of the webs of end brackets 106. The flanges 102 are connected to the webs by bolts. A similar construction might obviously be used for connecting bar 16 and 18 and brackets 30. The web 104 has an upper portion 106 which angles upwardly with respect to the idler and receives the end cap of the troughing roller. The end bracket-end cap connection in FIGURES 10 and 12 is the same as that shown in FIGURE 3. Also, the center brackets, side bars, and roller structure is the same. Load is transmitted to webs 104 from bar 100. However, bending of web 104 is resisted by the very nature of the construction, and the web will not twist or bend.

The location of the central roller vertically with respect to the side bars 100 can be altered as indicated by FIGURE 9.

FIGURES l0 and 12 also illustrate adaptation to rigid deck conveyors. This is accomplished by providing a base 108 adapted to rest on deck 110, and to be attached thereto by bolt 112.

While we have shown and described a preferred form of our invention, it will be understood by those skilled in the art that many changes in form and detail can be made within the scope of the appended claims, and, accordingly, we claim an exclusive right to all such forms and modifications.

We claim:

1. An idler for conveyors comprising a pair of spaced parallel side bars, a pair of end brackets inter-connecting said side bars adjacent each of the ends of said idler, idler rollers, each of said rollers having a shaft, means rigidly inter-connecting said idler roller shafts comprising spaced elements connected to said side bars and supported therein, said spaced elements vertically supporting said shafts inwardly of said end brackets, an end cap slidingly received in one of said end brackets and connected rigidly to one end of the group of rigidly connected shafts, said end cap and said spaced elements securing said shafts against rotation with respect to said end brackets and said side bars, said spaced elements and said end'cap being movable longitudinally with respect to said side bars and said one of said end brackets while said spaced elements and said end cap are in vertical load transmitting relationship respectively with said side bars and said one of said end brackets.

2. The idler set forth in claim 1 wherein said spaced elements comprise brackets, each of the latter brackets having integral arms extending through said side bars, said arms being in load transmitting contact with said side bars.

3. The idler of claim 1 wherein said end brackets have a web, said side bars having a flange at each end extending parallel to the web of the adjacent end bracket and being connected thereto in load transmitting relationship with said flanges constituting web stiffening means for said end brackets.

4. The idler of claim 1, including said idler having clamping means adapted to connect said idler to side frame idler supporting members, said clamping means each being provided with a bight adapted to receive one of the side frame supporting members for said idler, said bight being positioned substantially in the horizontal plane containing the uppermost point on the periphery of the uppermost roller of said idler intermediate the end rollers.

5. A conveyor idler comprising a center roller and a pair of end rollers spaced to opposite sides of said center roller, each of said rollers comprising shaft means extending outwardly of each end thereof, means securely interconnecting the shaft means at each end of said center roller with the adjacent shaft means of one of said side rollers to form a substantially fixedly inter-connected assemblage of rollers, each of said side rollers extending upwardly at an angle with respect to said central roller, frame means comprising a side bar extending alongside of said rollers, each of the second mentioned means being received in an opening within said side bar with said side bar providing vertical support to the latter means, said frame means further including end elements connected to the outer ends of the axles of said side rollers in vertically supporting relationship, each of said side bar openings being elongated lengthwise of said bar, said means interconnecting said axles being movable lengthwise of said bar in the latter opening and the connection between said assemblage of rollers and at least one of said end elements being such that the said assemblage is readily movable with respect to said frame means in a direction longitudinal of the later while said assemblage is in vertical load-supporting relationship with said bar, and With a load supported by said idler.

6. The idler of claim 5 wherein said end elements are non-rotatably connected to said shaft means.

7. The idler of claim 5 wherein said means interconnecting said roller shafts each comprise a pintle, said pintles extending into said side bar, means preventing Withdrawal of said pintles from said side bar.

8. The idler of claim 5 wherein the upper edge of said side bar is positioned vertically within an upper 'limita tion defined by the central axis of said central roller.

9. The idler of claim 5 wherein said end elements comprise flanges extending inwardly with respect to the shaft means of the rollers and the side bar, and end brackets connected to said flanges of said side bar, said end brackets having a web and a base, the outer ends of the shafts of the end rollers being supported by said end brackets, and said flanges constituting means for stiffening said end brackets.

10. The idler of claim 5, including said idler having clamp means adapted to supportingly connect said idler side frame members, said clamp means each having a bight adapted to receive one of the side frame members, which bight is positioned substantially in line with the plane containing the upper edge of the periphery of said center roller.

References Cited by the Examiner UNITED STATES PATENTS 1,584,565 5/1926 Langer 198-492 1,963,099 6/1934 Robins 198-202 2,539,792 1/1951 Niernitz 198192 X 2,743,810 5/1956 Armstrong 198-192 2,875,886 3/1959 Lo Presti et al.

SAMUEL F. COLEMAN, Primary Examiner.

JULIUS E. WEST, Examiner. 

1. AN IDLER FOR CONVEYORS COMPRISING A PAIR OF SPACED PARALLEL SIDE BARS, A PAIR OF END BRACKETS INTER-CONNECTING SAID SIDE BARS ADJACENT EACH OF THE ENDS OF SAID IDLER, IDLER ROLLERS, EACH OF SAID ROLLERS HAVING A SHAFT, MEANS RIGIDLY INTER-CONNECTING SAID IDLER ROLLER SHAFTS COMPRISING SPACED ELEMENTS CONNECTED TO SAID SIDE BARS AND SUPPORTED THEREIN, SAID SPACED ELEMENTS VERTICALLY SUPPORTING SAID SHAFTS INWARDLY OF SAID END BRACKETS, AN END CAP SLIDINGLY RECEIVED IN ONE OF SAID END BRACKETS AND CONNECTED RIGIDLY TO ONE END OF THE GROUP OF RIGIDLY CONNECTED SHAFTS, SAID END CAP AND SAID SPACED ELEMENTS SECURING SAID SHAFTS AGAINST ROTATION WITH RESPECT TO SAID END BRACKETS AND SAID SIDE BARS, SAID SPACED ELEMENTS AND SAID END CAP BEING MOVABLE LONGITUDINALLY WITH RESPECT TO SAID SIDE BARS AND SAID ONE OF SAID END BRACKETS WHILE SAID SPACED ELEMENTS AND SAID END CAP ARE IN VERTICAL LOAD TRANSMITTING RELATIONSHIP RESPECTIVELY WITH SAID SIDE BARS AND SAID ONE OF SAID END BRACKETS. 